Optimizing FSW process parameters using RSM and regression analysis for similar and dissimilar aluminium materials

Abstract

Aluminium hybrid composites were created using a modified stir casting process in this study. The casting yielded plates with dimensions of 100 mm, 50 mm, and 6 mm which were successfully butt connected using Friction Stir Welding (FSW). Four parameters were used to perform FSW; axial load, spindle speed, tool pin profile and aluminium material. The experiment was carried out utilizing the response surface approach of central composite design, which provides a pretty good prediction for all four parameters and 31 tests with a combination of input parameters were undertaken from the design. Regression analysis was used to examine the weld quality of welded specimens in terms of Ultimate Tensile Strength (UTS) and Hardness.